Method of producing a wax match shaft

ABSTRACT

A method of producing a shaft for a wax match which comprises the steps of continuously coating a web of combustible sheet material, such as paper, with a suitable impregnating material, such as wax; continuously compacting the web of sheet material into an elongated element of generally rounded cross-sectional configuration; progressively deforming the rounded element to present a polylateral, preferably a quadrilateral, crosssectional configuration with concave sides; allowing the deformed element to expand radially to reduce the concavity of the sides and preferably form a rectilinear polylateral cross-sectional configuration; and severing the element into individual match shafts.

United States Patent Inventor Cecil lllovo Kessler Johannesburg, SouthAfrica App]. No. 863,948 Filed Oct. 6, 1969 Patented Dec. 7, 1971Assignee Chet Industries (Proprietary) Limited Priority Oct. 14, 1968South Africa 68/6627 METHOD OF PRODUCING A WAX MATCH SHAFT 7 Claims, 10Drawing Figs.

US. Cl 264/136, 44/47, 144/51, 264/145, 264/280 Int. Cl ..B29c 17/02,B290 17/10, 829d 23/10 Field of Search 264/136,

[56] References Cited UNITED STATES PATENTS 3,180,911 4/1965 Muller264/119 3,185,552 5/1965 Berry..... 264/136 X 3,227,791 1/1966 Kiefer264/151 3,518,157 6/1970 Terry 264/119 X Primary Examiner Robert F.White Assistant Examiner-Richard R. Kucia Attorney-Young 8: ThompsonABSTRACT: A method of producing a shaft for a wax match which comprisesthe steps of continuously coating a web of combustible sheet material,such as paper, with a suitable impregnating material, such as wax;continuously compacting the web of sheet material into an elongatedelement of generally rounded cross-sectional configuration;progressively deforming the rounded element to present a polylateral,preferably a quadrilateral, cross-sectional configuration with concavesides; allowing the deformed element to expand radially to reduce theconcavity of the sides and preferably form a rectilinear polylateralcross-sectional configuration; and severing the element into individualmatch shafts.

PATENTEU DEE 71971 SHEET 3 [IF 3 hymn/me (Ea/4 K5964 E4 437 I" M WHTT/J.

METHOD OF PRODUCING A WAX MATCH SHAFT This invention relates to waxmatches.

For the purpose of this specification, the term wax match includes anymatch whose shaft is composed of combustible sheet material impregnatedand folded, rolled or other wise compacted into elongate form.

The shafts of wax matches are normally of circular cross section.

Hitherto, conventional wax matches have suffered from thedisadvantagethat their shafts are generally thin and not as rigid aswooden matches. Such a wax match is not as easy to strike as aconventional wooden match. Although such wax matches approach theeffectiveness of wooded matches if manipulated correctly, there has beensame bias against such wax matches in certain sectors of the buyingpublic.

This disadvantage has been overcome by increasing the cross-sectionaldimensions of the shafts. Hitherto, the increase in shaft thickness has,however, suffered from the disadvantage that the cost of production isincreased due to the increase in material that is required.

Another disadvantage with conventional wax matches with round shafts, itis that they cannot be produced satisfactorily by means of conventionalautomatic machines used for conventional wooden matches of rectangularcross section. For example, the mass application of striking heads onthe tips of round shafts is very difficult, if not impossible. It willbe appreciated that this increases the production costs of wax matchesso that they are not as competitive in relation to wooden matches asthey might be.

The difficulty with the mass application of striking heads on roundshafts, arises from the fact that it is standard practice with all matchmaking plants to insert match shafts into round apertures in holders fordipping into striking material in fluid form, a head of strikingmaterial being formed on the tip of each shaft during dipping.Experience has shown that whereas the rectangular shafts or splints ofconventional wooden matches engage securely in the round holes with thecomers of the shafts firmly engaging the surrounds of the apertures, thesame firm engagement cannot be obtained when round shafts are insertedinto round apertures. It will be appreciated that if the round aperturesare small enough to ensure a firm engagement with round shafts, theinsertion of the round shafts into the apertures becomes a problem anddamage to the ends of the shafts occur.

It has also been found that it is not satisfactory to insert the roundshafts into rectangular apertures.

The obvious solution to the problem would be to produce wax matches withshafts of rectangular cross-sectional configuration, but intensiveinvestigation by the applicant has indicated that it is not so simple toproduce a rectangular wax match shaft. Several foreign wax matchmanufactures of international repute have directed considerable effortto the production of a rectangular wax match shaft, but to the best ofapplicants knowledge no conspicuous success has been achieved as far. Infact, applicant's investigations have indicated that it is generallyaccepted in the wax match art that it is not a practically feasibleproposition to produce a rectangular wax match shaft.

It is an object of the present invention to overcome the abovedisadvantages and to provide a satisfactory and economical method ofproducing a wax match shaft of polylateral cross-sectionalconfiguration.

According to the invention a method of producing a wax match shaftincludes the steps of coating combustible sheet material with suitableimpregnating material; compacting the sheet material into an elongatedelement of generally rounded cross-sectional configuration; deformingthe rounded element to present a polylateral cross-sectionalconfiguration with concave sides; and allowing the deformed element toexpand radially at least to reduce the concavity of the sides.

It has been found that if the rounded element is only deformed to arectilinear crosssectional configuration, there is a tendency for thematerial of the element to expand radially outwardly so that the elementloses its rectilinear configuration and again approaches a roundedcross-sectional configuration. However, by proceeding further anddeforming the element so that it has a polylateral configuration withconcave sides, the tendency for the material of the element to expandradially urges the element back towards a rectilinear configuration.Tests have shown that with the method according to the invention, a neatsubstantially rectilinear polylateral crosssectional configuration canbe achieved.

The rounded elongated element may be produced in any suitable mannerfrom any suitable combustible sheet material, such as paper, which iscoated with any suitable impregnating material, such as wax, to give thefinished product the required degree of rigidity and combustibility. Anysuitable wax or a combination of waxes or a combination of at least onewax and any other suitable material may be used as impregnatingmaterial.

Preferably, the sheet material is first folded upon itself and is thenpassed through one or more dies to compact it and form it into anelongated element of rounded cross-sectional configuration.

The sheet material may be coated with impregnating material at anysuitable stage or stages before, during and/or after the folding andcompacting steps so that the folds of the rounded elongated element aresuitably impregnated to hold them in position.

The rounded element may be deformed into polylateral configuration inany suitable manner, such as by passing the element through one or moreshaping dies.

Preferably, the rounded element is deformed progressively to the concavepolylateral configuration. The element may accordingly be deformed topresent a rectilinear polylateral cross-sectional configuration prior tobeing deformed into the concave polylateral configuration.

The rounded element may be deformed to present a polylateralcross-sectional configuration with convex sides prior to being deformedinto the rectilinear cross-sectional configuration.

Preferably, the deformed element of concave polylateral configuration isallowed to expand to a substantially rectilinear configuration.

In a preferred embodiment of the invention, the element is deformed topresent a quadrilateral cross-sectional configura' tion and it ispreferred to have a substantially rectangular shaft after the concaveconfiguration has been allowed to expand radially.

A continuous element or an element of considerable length may be formedand then cut into required lengths to produce individual shafts, afterthe element has been deformed into concave polylateral configuration.

A preferred embodiment of the invention will be described by way ofexample with reference to the accompanying drawings in which:

FIG. I is a diagrammatic side view of apparatus suitable for carryingout the method according to the invention.

FIG. 2 is a perspective view of a folding device of the apparatus ofFIG. 1, operative to fold a travelling web of combustible material uponitself.

FIG. 3 is a perspective view of a further folding device which islocated downline of the device of FIG. 2 and is operative to fold thetravelling web further.

FIG. 4 is a perspective view of yet another folding device which islocated downline of the device of FIG. 3 and is operative to fold thetravelling web still further upon itself.

FIG. 5 is a perspective view, partly in section, of a compacting diewhich is located downline of the device of FIG. 4 and is operative tocompact the folded welb into an elongated element of roundedcross-sectional configuration.

FIG. 6 is a perspective view, partly in section, of a shaping dielocated downline of the compacting die of FIG. 5 and operative to deformthe rounded element to present a quadrilateral cross-sectionalconfiguration with convex sides.

FIG. 7 is a perspective view, partly in section, of another shaping dielocated downline of the shaping die of FIG. 6 and operative to deformthe element further to present a rectangular cross-sectionalconfiguration.

FIG. 8 is a perspective view, partly in section, of yet another shapingdie located downline of the shaping die of FIG. 7 and operative todeform the element further to present a quadrilateral cross-sectionalconfiguration with convex sides.

FIG. 9 is a side view, partly in section, of cutting means locateddownline of the shaping die of FIG. 8 and operative to sever acontinuous element passing from the shaping die of FIG. 8 intoindividual shafts of required length.

FIG. 10 is a perspective view to a larger scale of the cutting means ofFIG. 9.

A WEB 1 of combustible paper passes from a supply roll 2 roundtensioning rolls 3 and into a molten wax bath 4. The folding devices 5,6 and 7 of FIGS. 2, 3, and 4 respectively and the compacting die 8 ofFIG. 5, are located in sequence in wax bath 4. Folding device 5comprises a trapezium-shaped sheet of metal with its corners 5a bentover in the manner shown in FIG. 2. Folding device 7 is of similarconstruction. Folding device 6 presents U-shaped folding aperture 6awhich extends therethrough.

Web 1 is received as a flat sheet of material by folding device 5 and isfolded along opposite sides upon itself as it passes through device 5 toa folded web 10, as can be seen from FIG. 2. Web 1a is received byfolding aperture 60 of device 6 and is folded into the U-shaped web lb,as it passes through device 6, as can be seen from FIG. 3. Initiallywhen the web is threaded through the various devices when the apparatusis set up, web 1a is folded into U shape by hand and is passed throughfolding aperture 6a. The U-shaped web lb is received by folding device 7and folded still further to web as it passes through device 7, as can beseen from FIG. 4. Initially when the apparatus is set up, folded web lbis folded by hand into the formation of web 10 and passed through device7. Once the apparatus is started up, the web is fed through continuouslyand is folded automatically.

As the web passes through wax bath 4 in flat and folded form, the webbecomes coated with and the folds impregnated in wax.

The folded web 10 passes from folding device 7 to compacting die 8 whichpresents a bore 9 having a converging and serrated entry zone 9a, acentral compacting zone 9b of substantially uniform circular crosssection, and a flared outlet zone 9c. As web 10 passes through entryzone 9a, it is progressively compacted to the size of the central zone9b and the serrations crimp the material of the folded web 10 so that itis compressed in longitudinally fluted fashions. The compression isconsolidated in central zone 9b and a continuous, elongated element 10of generally rounded cross-sectional configuration emerges from die 8.As the rounded element 10 emerges from die 8, it is coated with anexternal wax layer 11.

If required, the rounded element f0 may be passed through one or morefurther compacting dies (not shown) in wax bath 4. After passing fromthe compacting die or dies, the rounded element 10 passes from wax bath4 and through a second wax bath 12 to ensure a satisfactory external waxcoating on the element.

From the second wax bath 12, rounded element 10 passes through coolingwater bath 13 to set the wax coating. Upon leaving the water bath 13,the cooled element 10 is subjected to a mechanical shaking operation bya rotary beater 14, to dislodge water adhering to the element.

So far the apparatus and method are conventional for the production of aconventional round wax match shaft.

From water bath 13, rounded element 10 passes over support rollers 15a,15b, 15c, 15d, 15e, and through shaping die 16 of FIG. 6, two shapingdies 17a, 17b, similar to die 17 of FIG. 7 and shaping die 18 of FIG. 8which are located in sequence to deform the rounded element 10progressively. Shaping dies 16, 17a, 17b and 18 are steam heated torender the wax on element 10 plastic. Drip trays 19 are providedunderneath the shaping dies.

Shaping die 16 represents an aperture 20 with a circular entry portion20a having a flared receiving mouth, a deforming portion 20b having aquadrilateral cross-sectional configuration with concave sides 21, and aconnecting portion 20c which converges from entry portion 20a todeforming portion 20b and which changes in cross-sectional configurationfrom that of circular entry portion 20a to that of quadrilateraldeforming portion 20b.

It will be appreciated that as the element 10 passes through deformingportion 20b of shaping die 16, the rounded configuration is deformed toa quadrilateral configuration with convex sides which is complementaryto the concave configuration of deforming portion 20b. When it leavesshaping die 16, the deformed element expands radially and assumes across-sectional configuration approaching a rounded configuration.

Shaping dies 17a, 17b are similar in construction to shaping die 16 withthe exception that the deforming portion 22b of aperture 22 isrectangular in cross-sectional configuration with straight sides 23. Asthe element passes through each of shaping dies 17a, 17b, the convexquadrilateral configuration is deformed to a rectangular configuration.When it leaves each of shaping dies 17a, 17b deformed element 10b againexpands radially towards a rounded configuration but it will beappreciated that with each deforming step, the expanded configurationcomes closer to being rectangular.

Shaping die 18 is similar to construction to shaping die 16 with theexception that the deforming portion 25b of aperture 25 has aquadrilateral cross-sectional configuration with convex sides 26. As theelement passes through shaping die 18 it is deformed to a quadrilateralcross-sectional configuration with concave sides. When the deformedelement 100, leaves shaping die 18, it again expands radially to reducethe concavity of the sides. By carefully relating the degree ofcompaction of the elongated element and the precise cross-sectionalconfiguration of the deforming portions of the shaping dies, as will bewithin the competence of a skilled man in the art, the degree of radialexpansion of the deformed element after it leaves final shaping die 18is such that it produces an element 100 having a substantiallyrectangular cross-sectional configuration as shown in FIG. 8.

The dimension x across comers is the same for the quadrilateraldeforming portions of the apertures of all the shaping dies 16, 17a, 17band 18.

Downline of the last shaping die 18 is a pair of feed rolls 27 betweenwhich the rectangular elongated element 10c passes on its way to cuttingmeans 28. Through frictional engagement with elongated element 10c, feedrolls 27 continuously draw web 1 off supply roll 2, continuously drawthe folded web through the folding and compacting means in wax bath 4and continuously draw the elongated element 10 through second wax bath12, through water bath 13 and through shaping dies 16, 17a, 17b and 18,before feeding the elongated element to cutting means 28.

Support rolls 15, feed rolls 27 and rotary cutting means 28 are drivenfrom common drive motor 29. In order to avoid tension being set up inthe elongated element 10 as it passes through shaping dies 16, 17 and18, first support roll 15a has the greatest speed of rotation, the speedof the succeeding support rolls decreasing progressively with roll 15ehaving the slowest speed of rotation which is equal to that of feedrolls 27.

So far, the apparatus has been described for the production of a singleelongated element 10. It will be appreciated that the apparatus may beadapted simultaneously to produce a plurality of juxtaposed elongatedelements.

FIGS. 9 and 10 illustrate rotary cutting means adapted to handle aplurality of elongated elements 10c simultaneously.

As shown in FIGS. 9 and 10, the cutting means 28 comprises a stationaryplate 30 presenting a plurality of apertures 31 through each of which anelongated element 100 can pass from feed rolls 27. The surrounds of eachaperture 31 constitute an anvil adapted to receive and support anelongated element 100 for severing. The outer edge of each aperture 21on the side opposite feed rolls 27 constitutes a cutting edge lying inthe plane of the outer face 30a of plate 30.

A pair of cutting blades 32 with cutting edges 320 are fast with andextend radially in opposite directions from drive shaft 33 which isrotatably coupled to drive motor 29. The blade cutting edges 32a lie inrotational planes located adjacent the plane of the outer surface 30a ofplate 311 so that upon rotation, blade cutting edges 32a successivelypass the anvil cutting edge at the outer end of each aperture 31 tosever an elongated element c extending therethrough into individualmatch shafts 34. The circumferential spacing between blade edges 32a,the speed of rotation of blades 32 and the rate of forward feed ofelongated elements 100, are related so that a match shaft 34 of requiredlength is cut off each time a blade edge 32a passes an aperture 31 inplate 30 through which an elongated element 10a extends.

As can be seen from FIG. 9, the inner face 321; of each blade 32 lies ina plane disposed at an acute angle to the plane of the outer face 30a ofplate 30 with the planes converging in the direction of rotation of theblades 32. The reason for this is that if blades 32 were locatedparallel to plate 30, the end of a continuously moving elongated element1111c emerging from an aperture 31 in plate 30 after it has been severedby the leading cutting edge 32a of a blade, would tend to contact theinner face 32b of the blade which is opposed to the outer face 30a ofplate 30. This would render the emerging end of the elongated element10c liable to damage which could cause problems during subsequent stagesin the manufacture of matches from severed shafts and/or could yieldfinished matches of inferior quality.

With the arrangement of FIG. 9 in which the inner faces 32b of blades 32lie at angles to the outer face 30a of plate 30, the spacing between ablade 32 and plate 30 increases rearwardly with the result that afterthe leading cutting edge 32a of a blade passes an aperture 31 in plate30, successive zones of the blade moving past the aperture 31 movesfurther away from the outlet end of the aperture 31 and remains clear ofthe emerging end of an advancing elongated element Me.

It will be appreciated that many variations in detail are possiblewithout departing from the scope of the appended claims. For example,the number of apertures 31 in plate 30 of cutting means may be changedto suit the number of elongated elements required to be producedsimultaneously. Thus, plate 30 may have only one aperture 31.

The apparatus may be provided with a positive variable speed drive unitbetween cutting means 28 and the remainder of the apparatus so thatindividual match shafts 34 of variable length can be cut off without anyadjustment to the apparatus being required, or than an adjustment of theratio of the variable speed drive unit to vary the speed of rotation ofcutting blades 32.

Instead of severing elongated element 100 into individual shafts 34immediately after the elongated element leaves final shaping die 18, theelement 100 may be suitably wound for subsequent cutting by separatecutting means using a rotary of reciprocating knife or knives.

It will be appreciated that instead of producing match shafts ofsubstantially rectangular cross-sectional configuration, shafts havingany suitable rectilinear polylateral crosssectional configuration suchas triangular, pentagonal or hexagonal may be produced by using shapingdies similar to dies 16, 17 and 18 having apertures with deformingportions of suitable cross-sectional configurations.

Where a match shaft having a thickness commensurate with that of aconventional wooden match is required, it is current practice to use twoor more superimposed layers of sheet material in order to obtain anelongated element of required thickness.

With the method of the present invention, the thickness of the endproduct may be increased by increasing the width of the sheet materialinstead of increasing the thickness of the sheet material by thesuperimposition of two or more sheets.

By increasin the width of the sheet material, material of in feriorstrengt to that WhICh 15 currently required, may be used without anydanger of the sheet material breaking. As a result, a saving in the costof the end product without any sacrifice in its quality may be achieved.

Tensioning rolls 3 permit the use of materials of relatively low tensilestrength but are not essential and may be omitted where material ofsuitable strength is used. Where tensioning rolls 3 are omitted, thefirst zone along the production line where tension is applied to the webof sheet material and the resultant elongated element, is at the firstsupport roll 150.

It has been found that a match shaft produced in accordance with theinvention engages firmly and satisfactorily with round apertures in adipping holder and that the mass application of striking heads to thetips of the individual shafts is facilitated.

The invention permits the production of wax matches which arecommensurate in shape, dimensions and rigidity with conventional woodenmatches and which is competitive in price.

it has been found that a wax match according to the inven' tion can bemade satisfactorily and economically by means of conventional automaticmatch making machines.

Iclairn:

1. A method of producing a wax match shaft comprising the steps ofcoating combustible sheet material with suitable impregnating material;compacting the sheet material into an elongated element of generallyrounded cross-sectional configuration; deforming the rounded element topresent a polylateral cross-sectional configuration with concave sides;and allowing the deformed element to expand radially at least to reducethe concavity of the sides.

2. A method as claimed in claim 1, wherein the rounded ele ment isdeformed progressively to the: concave polylateral configuration.

3. A method as claimed in claim 2, wherein the element is deformed topresent a rectilinear polylateral cross-sectional configuration prior tobeing deformed into the concave polylateral configuration.

41. A method as claimed in claim 1, wherein the deformed element toconcave polylateral configuration is allowed to expand to asubstantially rectilinear configuration.

5. A method as claimed in claim 1, wherein the element is deformed topresent a quadrilateral cross-sectional configuration.

6. A method as claimed in claim 3, wherein the rounded element is firstdeformed to present a polylateral cross-sectional configuration withconvex sides before being deformed to the rectilinear configuration.

7. A method of producing a wax match shaft comprising the steps offeeding a web of combustible material through molten wax; folding theweb laterally upon itself as it travels through the molten wax;compacting the folding web into an elongated element of generallyrounded configuration as it travels through the molten wax; deformingthe rounded element to present a polylateral cross-sectionalconfiguration with con vex sides; deforming the resultant element topresent a rectilinear polylateral cross-sectional configuration;deforming the resultant element to present a polylateral crosssectionalconfiguration with concave sides; allowing the resultant element toexpand radially to a substantially rectilinear configuration; andsevering the expanded element into individual match shafts.

2. A method as claimed in claim 1, wherein the rounded element isdeformed progressively to the concave polylateral configuration.
 3. Amethod as claimed in claim 2, wherein the element is deformed to presenta rectilinear polylateral cross-sectional configuration prior to beingdeformed into the concave polylateral configuration.
 4. A method asclaimed in claim 1, wherein the deformed element to concave polylateralconfiguration is allowed to expand to a substantially rectilinearconfiguration.
 5. A method as claimed in claim 1, wherein the element isdeformed to present a quadrilateral cross-sectional configuration.
 6. Amethod as claimed in claim 3, wherein the rounded element is firstdeformed to present a polylateral cross-sectional configuration withconvex sides before being deformed to the rectilinear configuration. 7.A method of producing a wax match shaft comprising the steps of feedinga web of combustible material through molten wax; folding the weblaterally upon itself as it travels through the molten wax; compactingthe folded web into an elongated element of generally roundedconfiguration as it travels through the molten wax; deforming therounded element to present a polylateral cross-sectional configurationwith convex sides; deforming the resultant element to present arectilinear polylateral cross-sectional configuration; deforming theresultant element to present a polylateral cross-sectional configurationwith concave sides; allowing the resultant element to expand radially toa substantially rectilinear configuration; and severing the expandedelement into individual match shafts.